1. Background & Pain Points in Algeria

In Algeria, demand for pharmaceuticals and health supplements is steadily increasing. More manufacturers are planning to fill and pack syrups and liquid supplements locally, not only for the domestic market but also with an eye on exports to neighboring North African and Middle Eastern countries.

The customer in this case is an Algerian pharmaceutical / nutraceutical producer manufacturing syrups and herbal-based liquids in 100–1500 ml bottles. As volumes grew, their semi-automatic filling and manual capping process revealed several issues:

• Long setup and changeover time when switching bottle sizes and volumes;

• Unstable filling accuracy, foaming and dripping of viscous syrups, causing product on the outer bottle surface and on the machine table, making audits more difficult;

• High labor dependence for bottle feeding, capping and labeling, in a context where skilled operators are not always easy to recruit and retain.

The customer needed a fully automatic 100–1500 ml syrup filling line that would meet pharmaceutical hygiene requirements, match Algerian power standards and reduce manual intervention while improving batch consistency and traceability.

2. Customer Profile & Application in Algeria

• Location: Algeria, supplying hospitals, pharmacies and retail chains;

• Products: Medicinal syrups, vitamin supplements, herbal / plant extract liquids;

• Bottle sizes: 100 / 150 / 200 / 250 / 500 / 1500 ml, in glass or plastic;

• Capacity targets:

  • 100 ml: 60–80 bottles/min;

  • 500–1500 ml: stable operation at approx. 20–30 bottles/min and 8–10 bottles/min;

• Compliance: Line must use hygienic materials for product-contact parts, include anti-drip and easy-clean designs, and allow for Arabic / French labeling and coding.

3. Solution: 100–1500 ml Syrup Filling & Capping Line for Algeria

To address these needs, Suzhou Lingyao Pharmaceutical Equipment Co., Ltd. supplied a 100–1500 ml Syrup Filling and Capping Line, consisting of four main machines:

(1) LYGP Turntable Bottle Supply Machine

• Bottle range: 100–1500 ml;

• Stable output: 20–80 bottles/min based on 100 ml;

• Frequency-controlled turntable automatically orients and feeds empty bottles to the conveyor, reducing manual handling;

• Built with a 3 mm SUS304 stainless-steel plate on a 12 mm carbon-steel base, ensuring flatness and smooth movement for both lightweight plastic and heavier glass bottles.

(2) LYGZ-6 Filling and Capping Machine (with CIP connection)

• Bottle volume: 100–1500 ml;

• Capacity: 60–80 bottles/min (100 ml);

• Filling system: rotary pumps with volume setting and fine adjustment via HMI; each pump can be calibrated individually, achieving ±0.5–1% accuracy;

• Product-contact parts: 316L stainless-steel needles and pharmaceutical-grade tubing; stainless-steel worktable and guardings meet hygienic requirements;

• Anti-drip and anti-foaming:

  • Needle movement is synchronized with a droplet collection tray to catch residual liquid as the needle rises, preventing syrup from dripping onto bottles and machine surfaces;

  • For foaming products, bottom-up diving filling can be used to significantly reduce foam;

• Capping: magnetic torque capping heads with adjustable torque, suitable for common plastic screw caps and pilfer-proof caps used in Algeria, with ≥99% capping qualification rate and overall product qualification rate ≥99.5%;

• Control: PLC + touch screen + inverter, with no-bottle-no-fill, bottle-not-in-place-no-fill, status display and self-diagnosis, making it easier for local operators to learn and use.

(3) LYLTJ-120 Vertical Self-Adhesive Labeling Machine

• Bottle diameter: 20–150 mm, covering 100–1500 ml formats;

• Labeling speed: 20–80 bottles/min, depending on label size;

• Label roll: max Ø300 mm, max label width 130 mm, core Ø76 mm—suitable for Arabic/French bilingual labels;

• Touch screen + PLC control with missing-bottle-no-label and missing-label alarm;

• Aluminum alloy + SUS304 stainless-steel frame, with provision for integration of ink-jet or laser coders for batch and expiry printing.

(4) LYGP Turntable Bottle Receiving Machine

• Synchronized with the upstream machines to collect finished bottles;

• Stainless-steel construction with variable speed, enabling smooth accumulation for manual packing or future automated case packing.

Together, these four machines form a complete line for feeding, filling, capping, labeling and collecting syrup bottles from 100 to 1500 ml. Recipe-based changeover on the HMI plus format parts allows quick switch between different sizes and SKUs, which is crucial for the Algerian plant’s mixed product portfolio.

4. Results & Feedback from the Algerian Customer

After installation and commissioning in Algeria, the customer reported the following improvements:

1. One line covers all main bottle sizes

   • The line now handles 100–1500 ml bottles on a single platform, reducing investment and maintenance costs compared with multiple small lines.

2. Better filling accuracy and hygiene

   • Rotary pump filling, 316L contact parts and the anti-drip design significantly reduce product on bottle exteriors and machine surfaces, making GMP-style housekeeping and inspections easier;

   • No-bottle-no-fill logic avoids product loss and contamination due to empty or misaligned bottles.

3. Higher automation, lower labor dependence

   • Bottle feeding, filling, capping, labeling and collection are fully automatic. Operators mainly focus on supplying bottles and caps and packing finished products, reducing headcount and workload per shift;

   • Centralized control and recipe management on the HMI shortens training time for new Algerian operators.

4. Ready for local compliance and future export

   • Electrical design follows Algerian power supply requirements, while full English technical documentation and validation files support regulatory and customer audits;

   • The customer regards this line as a reference configuration for future syrup workshop expansions aimed at both domestic and export markets.